Well I have just about an hour into the header install tonight and it looks like it is going to be a fairly easy install. Just looked through the B&B box and I guess I was one of the unlucky ones that they didn't include the o2 bung plugs for. So I won't be getting them on tonight..:nono:
Anyway, I haven't looked at the instructions so they might tell you to do these things anyway to make the job easier. But I will share how I am doing it anyway.
First I am doing all of the top side stuff first before jacking up the car.
I removed the strut tower brace, engine covers, and then to get extra room I took the coil brackets off with the coils and wires on them. I used a pair of long needle nose pliers grabed a hold of the sparkplug wire heat shields and a long screwdriver to pry them off with, they pulled right off. Get all that out of your way, I moved the battery cables around a little to get more room there too. Spark plugs were real easy to get out and I started to take off the header bolts. I sent my wife to Sears to get me a set of the ratchet wrenches as I didn't have them in metric. A 13 mm ratchet wrench should make very quick work of the header bolts. Here are a couple pics so far, the wife should be back any minute so I can finish the top stuff. No cuts yet...:thumbsup:
Bill
http://img.photobucket.com/albums/v466/HDMLNIUM/Headers-1.jpg
http://img.photobucket.com/albums/v466/HDMLNIUM/Headers-2.jpg

willsctsv

06-02-05, 06:03 PM

Hey, where's your FFV?:tease:

HDMLNIUM

06-02-05, 06:11 PM

FFV, I know I need to order one, the new and improved now in stock??

About and hour and a half of wrench time and all is done on the removal up top. o2's unplugged and everything unbolted and ready to jack up.
Here are a couple more pics...
Your friend for the header bolts if you are not using air..
http://img.photobucket.com/albums/v466/HDMLNIUM/Headers-3.jpg

All ready to jack up....
http://img.photobucket.com/albums/v466/HDMLNIUM/Headers-5.jpg
http://img.photobucket.com/albums/v466/HDMLNIUM/Headers-4.jpg
Well headed out to get her on jackstands before supper is ready...
Bill

CVP33

06-02-05, 06:11 PM

I should've taken the coil packs off. Those things were literally cutting into my wrists. As far as the O2 bungs. You'll need both. There are sensors both fore and aft of the cats. Read my posts for other hints, although you probably have me covered as you had the sense to pull the coil packs. Good luck.

cvp

CVP33

06-02-05, 06:12 PM

Don't know if I mentioned this before. The exhaust manifolds weight 23 lbs. apiece and the headers weigh 13 lbs. So you're also saving 20 lbs. off the front end. :thumbsup:

HDMLNIUM

06-02-05, 06:18 PM

CVP33,

I have 6 o2 bungs, 4 before and 2 after the cats, I need to get two plugs.
Some of us got the extra for tuning and to get airfuel on the dyno with out having to pull one of the pre-o2's.
I will check out your thread to see your hints, it is always good to share to help each other out..
Well spent to much time playing on the computer and supper is now ready.. lol
I guess I will jack her up a little later and get the manifolds and cats off..

Bill

wildwhl

06-02-05, 06:32 PM

HDMLNIUM -

Not certain..but a spark plug will plug that hole...maybe one of your original plugs (because you're putting new plugs in?)?

CVP33

06-02-05, 06:38 PM

The bung is actually larger than a spark plug. I also tried this prior to installing.

ssmith100

06-02-05, 06:42 PM

To plug the hole you need a 19mm oil drain plug off a Japanese vehicle. Any auto parts store will have them;)

Shane

HDMLNIUM

06-02-05, 06:42 PM

Yeah, I can slide the whole sparkplug right through the bung hole. Wait that dosen't sound right... lol:histeric:

Well done eating now so it is back to work...:thumbsup:

Bill

HDMLNIUM

06-02-05, 06:45 PM

To plug the hole you need a 19mm oil drain plug off a Japanese vehicle. Any auto parts store will have them;)

Shane

Thanks for the idea, I will give Napa a call and if they have them I guess the wife will be off for another road trip...:shhh:

Just got off the phone with Napa and they don't show any listing for 19mm drain plug..
Also checked the drain plug on my spare MR2 motor and it is too small...:banghead:
Back to the drawing board...

Do you think you could call me at home tonight and repeat that line, over and over, in a female British accent?

Talk about beating the cubes!:histeric:

HDMLNIUM

06-02-05, 09:55 PM

Well the car is back down on the ground for the night and I feel better after a nice shower. Got the factory manifolds and cats off. Two out of the 4 factory bolts after the cats broke while taking them off. I figured I would just put the headers on and get the plugs tomorrow. So I pulled the two o2 sensors from the pass side cat and put it on the B&B and installed that side pretty quick. Then I pulled out the after cat o2 sensor and put it in the new cat, all was still going good. Now here comes the pisser of the night that put an end to my fun. I could not budge the pre-cat o2 on the very last o2 to change. So being determind in all I got out a hammer and pounded it around till she came out, about 20 minutes to get it out. Junk, must of been stripped while being put in from the factory is my guess. So tomorrow after work I will have to go buy a new o2 and get a couple of plugs to finish her up with.
Thanks Rick for the info...

Crowan, I thought that sounded a little funny, I figured it would turn on a couple people here..:lildevil:

Thanks for the photos and update. Hope you can find an O2 easily...and can't wait to hear what your buttometer circa 19?? reports as to power improvements!

HDMLNIUM

06-02-05, 10:51 PM

Hey, Bill...just a reminder (probably too late for this one):

Rightie Tightie, Lefty Loosey :canttalk:

Thanks for the photos and update. Hope you can find an O2 easily...and can't wait to hear what your buttometer circa 19?? reports as to power improvements!

:histeric: :thumbsup: :banghead: Damnit I knew I should have paid more attention in school..
Believe it or not, I went left all the way, hit myself in the shin once when I missed the wrench..:histeric:
I can't wait to see how it sounds and feels, I will take her to the dyno after to see what it shows there too.

Bill

heavymetals

06-03-05, 12:37 AM

Has anyone installed a set of these and mated them to a Corsa exhaust system?

Any problems?

Thanks!

wildwhl

06-03-05, 01:26 AM

...I was thinking they'd mate to the stock exhaust no problem...but then I remembered the stock collector situation, so can't really be of any help. What is the Corsa front flange/connector like? Same as stock? Since I have the stock exhaust and headers sitting beside each other, I can check it out and see tomorrow.

heavymetals

06-03-05, 01:33 AM

Yeah same as stock.

Slight flange I believe.

I had a long conversation when I ordered the headers and I was assured no problem.

I just don't want to get it on a rack and have the dreaded "phone call".

Thanks!

CVP33

06-03-05, 06:52 AM

Bill,

Did you have any issues with the "fore position" passenger side O2 sensor? Mine was just barely long enough to connect and the wire is still pretty tight. I noticed that is was attached at the rear of the engine block but wasn't sure if that was just a tie-down or an actual connections.

As far as the manifold bolts go, I got you beat. I broke 3. I believe these were made to install once.

HDMLNIUM

06-03-05, 11:12 AM

CVP33,
The pre-cat o2 on the pass side was a little tight but she will be fine, after all wouldn't you prefer her to be a little tight than too loose... :histeric:
You could pop the harness off the back of the motor for more slack if you need it, but I don't think you need to.
Working late tonight and have to work tomorrow so if I have time to get the o2 and plugs I should have her back running Saturday night. Then put her back up and do the UUC shifter on Sunday...
What is everyone putting back in for sparkplugs, NGK tr55's should work pretty good and I think that is what I will pick up...

Bill

CVP33

06-03-05, 04:46 PM

I put stock back in. I doubt I'd notice the 3 HP gain of the others.

c5racr1

06-03-05, 07:09 PM

how much does the stock manifolds weigh verses teh headers?

HDMLNIUM

06-03-05, 07:26 PM

c5racr1,
Here is your answer, CVP33 posted the info on the first page..:thumbsup:

Don't know if I mentioned this before. The exhaust manifolds weight 23 lbs. apiece and the headers weigh 13 lbs. So you're also saving 20 lbs. off the front end. :thumbsup:

Also, car won't be going back together until next week. The bad part of living in the sticks (Maine) no one had the o2 sensor in the State. I have it coming from Mass and it won't be here until Monday. Next week is real busy for me at work so she will most likely go back together next weekend.. We will see if I have any spare time before then...

First, thanks Bill! The 13mm gear wrench was the total key. Also, remove the coil packs. Takes about 10 minutes, and can even make pulling the plug wires/heatshields easier. Way better with them out of the way. When replacing, plug the wires onto the spark plugs first, and then bolt the coil packs in place. This will give you enough room to use your hands on 7 of 8 cylinders.

:hmm: MRI's not my specialty for sure...but remember, I'm not a mechanic, just a silly printer ;)

Can I sleep at a Holiday Inn Express first? :want:

You're right, the bolts are tough to get to with the coil packs in place, but certainly not impossible (and no more than a 2 on the scale). Actually, now that I read my post again, I see a typo...I'd give the headers a 3. I do have a couple of light scratches on my wrists, and I did get pretty dirty (but mostly from changing wheels around). It didn't take long enough for a 6 pack though...so maybe a 2.5

I didn't realize you were afraid to get your hands dirty, Urby? And you bought a pushrod motor american car? :cookoo:

HDMLNIUM

06-05-05, 08:37 PM

Headers are a 3 I would say on that scale..

UUC shifter was a 2

Reading a Brain MRI scan I give that a 1, Hey I never said I would be able to read it right... But my hands would be clean and no cuts...:histeric:

Bill

HDMLNIUM

06-06-05, 04:32 PM

Just an update, all I am waiting on is the new o2 sensor to show up so I can try this baby out. I want to fire her up and give her a listen so bad...:banghead:

Anyway, everything is back together, the UUC shifter is in and as soon as I get home from work tomorrow with the new o2 she will be running..
All in all the Header and the UUC shifter were pretty easy installs..
Later this week I hope to get all of the BMR parts in and see how that feels.
Bill